LET'S TALK ABOUT 3D SCANNING

1. Background

Chris loves driving around Lake Tahoe in his open-top Jeep Wrangler, enjoying the blue skies and fresh air. The Jeep Wrangler is his vehicle of choice for fun adventures and transporting his wet dog after a swim in the lake. One day, Chris noticed that one of the auxiliary light mount brackets at the front had cracked. Initially, he planned to search for replacement parts, but then he heard about Growshapes' 3D scanning technology. Intrigued by the idea of reverse engineering and 3D printing the bracket, he contacted Growshapes to explore the possibilities. The original bracket mounts were made of plastic and had cracked under stress, so Chris was looking for a solution that would be stronger and more durable than the originals.

​2. The Tools and Method

Growshapes used Einscan Pro 2X 2020 to 3D scan the cracked plastic bracket mount and worked with an engineer at Uniformity Labs to reverse engineer and create a metal 3D-printed replica.

3. The Reverse Engineering Process

Step 1: 3D scan the bracket mount to capture complex geometries using Einscan Pro 2X 2020

Growshapes received the broken plastic bracket mount from Chris. Judging from the size of the part, we decided the best scanning tool was the EinScan Pro 2X 2020 that can capture intricate details with high accuracy, especially in fixed scan mode using it in conjunction with the automated turntable.  For small objects, EinScan Pro 2X is the way to go for sure.  It captures fine details as point cloud data, then converts it into a mesh that can be exported as an .stl file into a CAD software such as Solidworks. 

Growshapes 3D scanned the black plastic part that had a fracture on the main wall of the bracket mount. You can see the fracture in the scan results below.  We scanned the bracket in fixed mode to digitally capture accurate data of this small part.  Fixed scan mode was chosen to use the 3D scanner with the automated turntable. There was no need to put any markers on the parts as the scan was aligned to the markers on the turntable and didn’t even require spraying even though the part was black. The Einscan Pro 2X 2020 uses structured white light technology and the software allows for the capture of dark parts.

The steps that were taken from editing the scan files to  print:

1. The scan was imported into CAD software as points and surfaces
2. Measurements were collected and construction geometry such as planes, contours, etc. were extracted from the scan data
3. The bracket was modeled from this reference geometry generated by the scanned data
4. That design was then "optimized" for additive manufacturing, removing as much material as possible, adding lattices
5. The optimized design was exported from CAD as an STL file
6. The STL file was sliced in Netfabb using the latest EBPA
7. The SLM 125 (for AlSi10Mg) and SLM 280 (for 316L) were prepared and the prints launched
8. The builds were removed from the machine, cut off of the build plate, and sonicated
9. Supports were removed by hand

Some of the challenges Marlon faced specifically for optimizing for additive manufacturing:

• Required other software beyond just the CAD software. Other software, such as nTopology, simplifies modeling more organic shapes conducive to additive manufacturing
• Limited information about the end use of the bracket (how much it was going to support, environmental conditions, etc thus had to make assumptions

Things specifically engineered to optimize for 3D printing:

• Material removal for light weighting
• Lattices for additional stiffness
• Kept overhangs to 45 degrees to minimize support and post-processing
• Made assumptions regarding loading and boundary conditions

The original bracket was made from injection molded plastic but the plastic gave way to stress over time. The metal bracket should be stronger than the original plastic bracket mounts.  Marlon decided to use 316L (stainless steel) as is resistant to corrosion in harsh weather and can withstand varying temperatures. Injection molding requires a substantial investment in tooling thus requires volume production but with additive manufacturing, one-off print is possible with drastically shorter lead times. 
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See the full additive manufacturing workflow​ below:

Chris is happy with the new and improved auxiliary light bracket mount that is stronger than the original one that came with the Jeep Wrangler.  He won't have to worry about having another stress fracture in the bracket mount.  Reverse Engineering is not just about replicating but also about improving upon the original design!  

Check out the mounting brackets that were fixed onto the Jeep Wrangler below.

Have you ever wondered why your 3D scanner won’t capture the surface of certain objects? Or have you become frustrated by getting an incomplete 3D scan and scratching your head trying to figure out what you did wrong? Various 3D scanning technologies exist, i.e. structured light scanners, laser scanners, and photogrammetry, yet all have challenges due to the limitations of physics such as light passing through transparent objects.

The surface of the object can make 3D scanning challenging.  The below objects are usually challenging to 3D scan.

1. Highly detailed objects
2. Dark surfaces such as black objects
3. Reflective objects with shiny surfaces
4. Bright, colorful patterns
5. Humans

Fortunately, the key is to find the right 3D scanner for your objective and deploy best practices. Read on to find out which scanner would be best to overcome these challenges!

1. Highly-detailed objects

When capturing highly detailed objects, it is essential to ensure that the 3D scanning parameters are adjusted to capture sharp edges and intricate details accurately for the best results. The default scan parameters may not always capture these elements with sufficient detail and high precision. However, by customizing the settings, you can obtain an accurate 3D model that faithfully represents the object without losing any important details. One crucial setting to adjust is the point distance, which determines the resolution of the scan. By selecting a smaller point distance, you can achieve a higher resolution and capture finer details even for medium-sized objects.
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The EinScan Pro Series multifunctional 3D scanner is an excellent choice for scanning detailed objects, offering an adjustable resolution of up to 0.2mm. With this scanner, you can reproduce intricate details with highest accuracy, ensuring a high level of precision in your 3D models captured as a .stl file. Furthermore, the EinScan Pro Series provides efficient 3D scanning capabilities and a user-friendly experience, making it an ideal solution for capturing highly detailed objects with ease.

If you require a 3D scanner capable of capturing intricate details, a desktop 3D scanner would be a suitable choice. Among the recommended options are the EinScan SE, EinScan SP, Transcan C, EinScan Pro Series set up on a tripod. The Transcan C, in particular, offers an impressive resolution of up to 0.035mm, ensuring excellent detail reproduction.

It's important to note that the highest resolution scans result in denser point clouds, which means more data and larger file sizes. Additionally, the software will take longer to process a greater amount of data. Therefore, it is generally recommended to use fine resolution settings for small or medium-sized objects. Scanning larger objects with a desktop 3D scanner or tripod setup can be time-consuming and labor-intensive as well. Before choosing a scanning method, consider the size of your objects. Finding the right balance between scan quality and efficiency is crucial. Assess the trade-off between the level of detail required and the time and resources available for scanning larger objects. By carefully considering these factors, you can select the most appropriate scanning method for your specific needs.

2. Dark surfaces

If you've encountered difficulties in 3D scanning dark objects, you're not alone. Dark surfaces pose a common challenge in the 3D scanning process due to their high light absorption. Just like wearing a dark-colored shirt under the sun, dark colors absorb more light, which makes it difficult for 3D scanners to accurately capture their surface details.

To overcome this challenge, there are a few techniques you can employ. One approach is to attach adhesive markers or targets to the object. These markers act as reference points that assist the 3D scanner in tracking and aligning the scan data. Another option is to apply white powder as simple as baby powder or Aesub Blue 3d scanning spray to the dark surface, which helps enhance the reflection of light and improve scan results. However, these methods can be time-consuming, and messy, and may not be suitable for delicate objects.

Fortunately, not all light sources are created equal, and certain 3D scanners offer better performance when scanning dark surfaces. A more powerful laser and the use of blue light can be effective in capturing dark objects. Blue light has a narrower wavelength compared to white or red light, allowing for better resolution and detail capture.

​The EinScan HX is equipped with powerful laser lines and blue LED light in its fast mode. This combination of technologies enables efficient scanning of dark surfaces without the need for markers or white spray. In just minutes, the EinScan HX can produce high-quality scans, even for objects as challenging as a black lion sculpture.
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By utilizing advanced 3D scanning technologies specifically designed for dark surfaces, you can achieve accurate and detailed scans without the additional steps of applying markers or powder.

3. Reflective or shiny surfaces

Scanning objects with siny and reflective surfaces present another common challenge in 3D scanning. While dark surfaces absorb light, shiny surfaces, such as mirrors or shiny metal parts, disperse and reflect light in various directions, making it difficult for 3D scanners to accurately capture the object's details. Remember how 3D scanners work.  3D scanners project light onto objects, and measure how the light is returned or deformed, but reflections make it impossible to read.
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In industries like machinery or automotive, shiny and metallic parts are often scanned, necessitating specific techniques to overcome this challenge. Markers and the power of the light source play crucial roles in scanning shiny surfaces. A more powerful and high-quality light source significantly improves a 3D scanner's ability to capture data from shiny objects. In some cases, especially with medium and large-sized objects, markers may be necessary to ensure excellent scanning results. Using magnet markers can provide a quick, easy, and non-destructive removal solution as well.
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The EinScan HX, equipped with a powerful blue laser light source and marker recognition capability, is designed to address this 3D scanning challenge. Among all the EinScan Series 3D scanners, it is the only one capable of effectively capturing shiny objects. Its advanced features enable successful scanning of metallic surfaces, as demonstrated in the example below.

4. Colorful object

When scanning brightly colored objects, it is crucial to ensure accurate representation of the object's color information in the generated data for good results. This heavily relies on the pixel count or digital resolution of the texture camera used. Pixel count is typically measured in megapixels (MP), where one MP equals one thousand pixels. Insufficient camera resolution can result in color distortion and loss of detail.

The good news is that all EinScan 3D scanners can capture texture data. The EinScan H and HX models come equipped with built-in color cameras, while the Pro Series offers color capture functionality through an optional color pack add-on.
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Different 3D scanner models offer varying camera resolutions to accommodate different budgets and specific use cases.

For those seeking the highest level of color detail, the Transcan C 3D scanner is the ideal choice. It features an exclusive 12-megapixel texture camera, offering superior color detail with its higher pixel count. With the Transcan C, you can expect to capture the finest color details and achieve excellent color accuracy in your 3D scans.

5.  Scanning humans

When it comes to 3D scanning the human body, there are three key challenges that need to be considered: (1) maintaining stillness, (2) avoiding direct light in the eyes, and (3) successfully capturing fine details such as hair.

Firstly, it is crucial for the subject to remain as still as possible during the scanning process. Even the slightest movement, such as blinking or shivering, can introduce inaccuracies in the final 3D model.

Secondly, some scanners utilize intense LED lights that can be uncomfortable or temporarily impair vision if directly exposed to the eyes. This can cause discomfort and hinder the scanning experience.

Lastly, capturing the intricate details of human hair presents a challenge due to its thin nature and the potential for it to blend together or appear less defined in the scan.

Fortunately, specialized 3D scanners have been developed to address these specific challenges. The EinScan H2 and Einstar are excellent examples. These scanners incorporate "non-rigid" algorithms in their software that automatically compensate for slight body movements, reducing the impact of any minor shifts during scanning.

Additionally, they utilize infrared rays instead of LED lights or lasers, eliminating any discomfort or vision impairment. Infrared technology proves effective at capturing both dark and light-colored hair, ensuring accurate representation of fine hair details in the resulting 3D scans.

When it comes to body 3D scanning, the EinScan H and Einstar, along with their dedicated software, serve as efficient and reliable allies, helping overcome the challenges associated with scanning the human body. As you can see below, EinScan H will give you much more detail than the Einstar.

Conclusion

Despite the challenges posed by certain surfaces, to get the final result you want is possible by employing the right combination of hardware and software solutions.

The EinScan series offers a wide range of 3D scanners designed to accommodate various situations and budgets. Each scanner within the EinScan lineup possesses unique features and specifications, making them suitable for different users and applications. Whether you're scanning complex surfaces, intricate details, or specific objects, there is an EinScan 3D scanner that fits your requirements.

If you find yourself uncertain about scanning a particular surface or need guidance in selecting the most suitable scanning solution, don't hesitate to reach out to Growshapes! Our team is available to provide assistance and support to ensure you choose the optimal scanner for your needs.

For those interested in delving deeper into the world of 3D scanning, we invite you to explore our webinar titled "Things You Should Know Before Buying a 3D Scanner." This webinar offers valuable insights and knowledge to help you make informed decisions.

You can also refer to this blog "Which handheld 3D scanner is best for me?"  
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We are committed to providing you with the necessary resources and support to ensure your 3D scanning endeavors are successful and tailored to your specific needs.  To try before you buy, contact us too!

5.  User Account Center

In order to provide users a platform for scanner management and learn about all things EinScan, the all new User Account Center has been added. By downloading ExScan V3.7, you will get a free user account to get the software started. Offline activation is accessible without contacting support person now as well.  Please make sure your device is connected for log in and activation.

Finally, please make sure your NVIDIA graphics card has the compute capability of 5.0 or above by checking your graphics card capability from here: https://developer.nvidia.com/cuda-gpus#compute